As industrial facilities seek smarter, more sustainable cooling solutions, many are looking to integrate dry coolers into their existing infrastructure. These systems are perfect for companies looking for low-maintenance, energy-efficient chiller substitutes, particularly in regions where ambient temperatures frequently dip below process fluid requirements.
So, how does one go about integrating dry cooling systems? In this article, we’ll discuss:
- What is a Dry Cooler
- Why Integrate a Dry Cooler
- How Do Dry Coolers Fit into Existing Systems
- Industries That Benefit from Dry Coolers
- Delta T Systems’ Dry Cooler System
What is a Dry Cooler?
A dry cooler is a closed-loop heat exchanger that uses ambient air to cool a water or water-glycol mixture circulating through its coils. The fans move air over these coils to transfer heat, eliminating the need for evaporating water. While water is still used in the system, it’s contained in a sealed loop and not consumed in the cooling process like in evaporative cooling towers.
To learn more, read our blog, “What is a Dry Cooler (Free Cooler) & How Does It Work?”
Why Integrate a Dry Cooler?
1. Significant Water Reduction
Dry coolers operate with a closed-loop fluid system, using the same water or water/glycol mix repeatedly. This setup dramatically cuts down on water usage compared to cooling towers that require constant makeup water due to evaporation.
2. Lower Maintenance Needs
Since the fluid doesn’t evaporate or get exposed to outside air, the system decreases issues like scaling, fouling, or biological growth. This results in fewer chemical treatments and less equipment downtime.
3. Energy Savings with Dry Cooling
In cooler weather, dry coolers can often meet cooling demands using just ambient air– no need to run energy-intensive chillers. This “dry cooling” approach reduces electricity use and overall operating costs.
4. Cleaner and Quieter Operation
Dry coolers don’t emit mist or introduce contaminants into the environment, and they typically run more quietly than cooling towers.
5. Stable Temperature Control
Equipped with variable-speed fans and advanced controls, modern-day coolers can maintain precise fluid temperatures even as conditions change.
How Do Dry Coolers Fit Into Existing Systems
There are a few effective ways to integrate dry coolers:
- Parallel with Chillers: The dry cooler shares the load and takes over when conditions allow for dry cooling.
- Pre-Cooling: Installed ahead of a chiller, the dry cooler lowers the fluid temperature to ease the chiller’s workload.
- Cooling Tower Replacement: In systems where open cooling towers are inefficient or high-maintenance, a dry cooler can serve as a low-water alternative.
- Standalone for Process Cooling: For applications like molding or fermentation, dry coolers offer stable cooling without additional infrastructure.
Each approach depends on factors like load, climate, and space availability. Design should consider pump capacity, glycol concentration for freeze protection, and proper control integration.
Can You Combine a Dry Cooler and a Chiller Into a Single Unit?
Yes— with Delta T Systems’ Dry Cooler/Chiller Combo. Rather than sourcing and commissioning a dry cooler and chiller as two separate pieces of equipment, the Combo unit factory-assembles both into a single, function-tested package with one controller managing the whole system.
A proprietary control program continuously monitors ambient conditions and automatically decides which mode to run:
- When outdoor temperatures are low enough, the unit relies entirely on the dry cooler coils and variable-speed fans, drawing no power from the compressor at all.
- As ambient temperatures rise, the same control brings the hermetically sealed, variable-speed compressor online to maintain the setpoint mechanically.
Because the switch between modes is automatic, the unit captures free cooling whenever conditions allow it, rather than relying on an operator to catch the ideal moments to switch over manually. This can significantly reduce compressor run hours and energy use compared to a stand-alone chiller.
You can learn more about combining dry coolers and chillers in our article, “What is a Dry Cooler (Free Cooler) & How Does It Work?”
Industries that Benefit
Any application needing stable, reliable cooling can benefit from switching to or supplementing with dry coolers. Dry coolers support a wide range of sectors, including:
- Plastics processing
- Rubber applications
- Food and beverage
- Injection molding
- Pharmaceuticals
- Cleanrooms
- Data center cooling
You can learn more in our article, “Common Industries That Benefit From Dry Cooling Technology”.
Check out Delta T Systems’ Dry Cooler & Chiller Combo Units
Delta T Systems provides dry cooler systems and dry cooler/chiller combo units that are ready for integration. Our equipment uses closed-loop designs, advanced controls, and modular construction. Our engineering team assists with equipment selection, layout planning, and system commissioning. We also support integration with existing infrastructure using options like PLCs and remote monitoring.
When integrated properly, a dry cooler can upgrade your cooling system with minimal disruption. Delta T Systems can help evaluate your setup and recommend a dry cooling solution that fits your needs.